Method and apparatus for testing emissive cathodes

ABSTRACT

A method of electrically testing pixel functionality is provided comprising releasably disposing a wafer in a socket. The wafer has at least one baseplate comprised of cathode emitters arranged in pixels. The socket has pads. The socket pads are contacted with test pins, and each of the pixels is addressed individually, thereby causing the cathode emitters to emit electrons in a current. The current is collected from each of the pixels on an anode screen. Alternatively, the anode card may have pins, and these pins contact pads on the baseplate. The baseplate, or substrate with baseplates, does not require a socket with pins.

This is a continuation of application Ser. No. 08/383,269 filed on Feb. 3, 1995 now abandoned which is a continuation of Ser. No. 08/377,320 filed Jan. 24, 1995, now abandoned.

FIELD OF THE INVENTION

This invention relates to matrix addressable display devices, and more particularly to a method and apparatus for testing the emission of the display.

BACKGROUND OF THE INVENTION

Quality assurance requires the testing of manufactured products to determine if they will function over a given set of parameters. Testing is performed on a random sampling of products from the production lines, or in some industries, on every product which is manufactured.

Optical measurements are currently performed on display devices at the final stages of display testing. Optical measurement is accomplished by turning on all the cathode emitters in a pixel, and visually observing them. This method is extremely subjective, as it relies on the judgement of the individual peering at the screen.

Photon Dynamics of Milipitas, Calif. employs a method in which photons from a full display (i.e., substantially all of the pixels are turned "on" at the same time) are measured. A completed display device is optically tested by measuring the light emitted from the display.

There are several drawbacks to the above described optical method. For example, the process is very expensive, as it requires sophisticated optics and processing algorithms in order to determine the relative number of functional pixels.

Additionally, the optical systems require closely spaced anodes with respect to the cathode in order for the inspection optics to obtain accurate measurements. Therefore, the optical systems are not practical for testing display baseplates prior to their assembly in a field emission device.

Other methods used to measure current emitted by field emitter devices employ a positively biased electrode. However, these methods also measure the total current emitted by substantially all of the pixels in the completed unit. Therefore, these methods are also limited to measuring the operation of the device as a whole.

There still exists a need for a method to measure the current emitted by individual pixels in the display in order to determine their functionality, as well as the total number of functioning pixels (also known as the "yield"). Additionally, manufacturing realities require that the functionality of the individual pixels is measured in a rapid fashion.

SUMMARY OF THE INVENTION

The functionality of individual pixels in an addressable emissive cathode is determined by measuring the emitted current from a single pixel or from a small group of pixels. The current is measured on an anode screen disposed above the cathode emitters, thereby enabling the anode to collect electrons emitted from the cathodes. The collected current is compared to known parameters in order to determine whether the individual pixel site is functional.

The method of the present invention allows for the testing of cathode emitters in a vacuum chamber through the use of probe cards or sockets, and an anode. This format allows for the testing of approximately 100,000 pixels in less than 30 seconds, thereby expanding testing capabilities. Not only does the present technique permit faster testing, but also a less expensive alternative to the functionality tests used for individual pixels.

One advantage of the test method of the present invention is that it enables rapid determination of individual pixel functionality of the cathode emitters used in field emission type displays, or other similarly addressed matrix displays. For example, the present test method is suitable for displays that are actively or passively addressed.

The method of the present invention permits testing of the cathode emitters as a baseplate. Additionally, the use of an anode which luminesces under electron bombardment permits the measurement of emitted photons to determine pixel functionality.

The present invention is employed to sequence through all of the pixels, one or more at a time. Additionally, there is no required spacing for the anode in order to achieve accurate measurement. Further the present invention can be used with current optical methods to enhance the value of those methods.

One aspect of the invention comprises a method of electrically testing pixel functionality which comprises releasably disposing a wafer in a socket. The wafer has at least one baseplate comprised of cathode emitters arranged in pixels. The socket has pads. The socket pads are contacted with test pins, and each of the pixels is addressed individually, thereby causing the cathode emitters to emit electrons in a current. The current is collected from each of the pixels on an anode plate.

Another aspect of the invention comprises an anode card useful for measuring emitted current which comprises: a socket in which to dispose a substrate having cathodes; an anode disposed opposite the socket for collecting emissions from the cathodes, a high vacuum existing between the socket and the anode; and contact pins disposed on the anode for making contact with the substrate.

A further aspect of the invention comprises an apparatus useful for testing emissive cathodes comprising: a transparent collector having phosphors disposed thereon, and a wafer support device for releasably supporting a wafer opposite the transparent collector. The socket has contact pins for contacting the wafer. A high vacuum exists between the transparent collector and the wafer support device.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be better understood from reading the following description of non-limitative embodiments, with reference to the attached drawings, wherein below:

FIG. 1 is a schematic cross-section of a pixel of an illustrative field emission display having emitter tips;

FIGS. 2A-C are schematic top-views of the field emission display illustrating the relative location of the pixels of FIG. 1, illustrating a testing sequence, according to the present invention;

FIG. 3 is a schematic cross-section of the pixels of FIG. 2, illustrating an electrical method used to test the current of the pixels, according to the present invention;

FIG. 4 is a schematic cross-section of the pixels of FIG. 2, illustrating an optical method used to test the photons emitted by the pixels, according to the present invention; and

FIG. 5 is a flow chart illustrating the process of pixel testing according to the process of the present invention;

FIGS. 6A-B are schematic views of an anode card, with the pins on the anode according to the present invention; and

FIGS. 7A-B are schematic views of the anode card with the pins on the socket, according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, a representative field emission display employing a display segment 22 is depicted. Each display segment 22 is capable of displaying a pixel of information, or a portion of a pixel, as, for example, one green dot of a red/green/blue full-color triad pixel.

Preferably, a single crystal silicon layer serves as a substrate 11. Alternatively, amorphous silicon deposited on an underlying substrate comprised largely of glass or other combination may be used as long as a material capable of conducting electrical current is present on the surface of a substrate so that it can be patterned and etched to form micro-cathodes 13.

At a field emission site, a micro-cathode 13 has been constructed on top of the substrate 11. The micro-cathode 13 is a protuberance which may have a variety of shapes, such as pyramidal, conical, or other geometry which has a fine micro-point for the emission of electrons. Surrounding the micro-cathode 13, is a grid structure 15. When a voltage differential, through source 20, is applied between the cathode 13 and the grid 15, a stream of electrons 17 is emitted toward a phosphor coated screen 16. Screen 16 is an anode.

The electron emission tip 13 is integral with substrate 11, and serves as a cathode. Gate 15 serves as a grid structure for applying an electrical field potential to its respective cathode 13.

A dielectric insulating layer 14 is deposited on the conductive cathode 13, which cathode 13 can be formed from the substrate or from one or more deposited conductive films, such as a chromium amorphous silicon bilayer. The insulator 14 also has an opening at the field emission site location.

Disposed between said faceplate 16 and said baseplate 21 are located spacer support structures 18 which function to support the atmospheric pressure which exists on the electrode

faceplate 16 as a result of the vacuum which is created between the baseplate 21 and faceplate 16 for the proper functioning of the emitter tips 13.

The baseplate 21 of the invention comprises a matrix addressable array of cold cathode emission structures 13, the substrate 11 on which the emission structures 13 are created, the insulating layer 14, and the anode grid 15.

The present invention provides a method and apparatus useful for testing cathodes emitters, which cathode emitters are frequently used in field emitter display devices. The testing procedure of the present invention is discussed in terms of field emission displays. However, one having ordinary skill in the art, upon being apprised of the present invention will realize its applicability to other matrix addressable displays or devices having emissive cathodes.

The field emitter displays have cathode emission structures 13 which emit electrons into a vacuum environment. For purposes of display devices, the electrons are collected on an anode 16 which is coated with phosphors 19. The phosphors 19 luminesce under electron 17 bombardment, thereby creating the colored light which forms the displayed image.

During the operation of the display, individual pixels 22 are turned on, so that the pixels 22 emit a controlled amount of current. Each pixel contains one or more cathode emitter structures 13. FIGS. 2A-C illustrate that the control of the pixels 22 is accomplished by a matrix addressable system of rows R₁ . . . R_(m), and columns C₁ . . . C_(n). Pixel sites 22 are disposed at the intersection of the rows and columns, and are thereby addressable by their location. In this manner, individual pixels 22 are addressable one or more at a time.

A knowledge of the yield of pixels on the baseplate 21 is essential to the production of field emission displays and other devices. Statistically relevant information can only be obtained by measuring the functionality of every pixel at the earliest opportunity. This information is needed to provide feedback for process modification, trouble shooting, and yield enhancement.

The inability to test baseplates 21 means that yield analysis and process problems remain unknown until the assembly and testing of the completed display. This is a costly approach as defective baseplates are processed into a complete display before the problem is identified. The feedback to the fabrication process is limited by the additional process steps, and by increasing the time until the defects are discovered.

The test method of the present invention is performed by turning on all of the pixels of the cathode 12 for "burn in," and to establish an equilibrium. "Burn in" refers to stressing the devices through electrical cycling, thereby causing any defective parts to fail.

The drive cycle is started in which individual pixels are turned on one at a time or in small groups. This application will refer to the pattern of addressing the pixels 22 as "sequencing," and it is to be understood that the pixels 22 are addressable in a variety of patterns or in a row or column. Sequencing through the pixels 22 enables all of the pixels 22 to be addressed and tested for functionality.

The drive cycle is illustrated in FIGS. 2A-C. A column (C₁) is turned on, as well as a row (R₁), thereby causing the pixel 22 located at their intersection to emit electrons 17. The emitted electrons create a current which is collected on an anode plate 16 disposed above the cathode emitters 13. The anode 16 has a positive bias with respect to the cathodes 13, thereby enabling the anode 16 to collect the electrons 17.

The collected current is measured and compared with known data for good pulse current. See, for example, FIG. 3. The current magnitude is measured to determine whether the current is above or below the known value. Alternatively, the shape of the pulse (rise time, fall time, etc.) is measured to determine whether the pixel 22 responds properly in a given time frame.

The measurement techniques include coupling the current through a capacitor; measuring the voltage across a resistor; or directly measuring the current through a power source. The method chosen varies with the amount of anode voltage used, the size of the current pulse, and the speed with which the measurement is taken.

After the current from the first pixel is measured, a second pixel in the same or another column is addressed. The current from the second pixel is measured, and the process is repeated until all of the pixels have been measured.

A delay time between each measurement is incorporated to allow for data processing, and for decay of the pulse when the time response of the system is slow. For example, pixel (P₁) is turned on for 100 μsec. After which no pixel is turned on for 100 μsec. Then pixel (P₂) is turned on for 100 μsec, and so on. Using this 200 μsec. total time (i.e., pulse plus delay time), the system is capable of measuring approximately 100,000 pixels in about 20 seconds. This is especially useful in displays having more than 10,000 pixels.

Of course, depending on the size of the baseplate 21 and the number of pixels thereon, the timing of the individual pixel test may vary. The preferable range for pulse plus delay is approximately 10 μsec to 10 msec.

This is quite a significant advancement over the visual inspection methods currently used, as the present method enables the electrical testing of substantially every pixel 22 individually, and in a rapid fashion.

Non-functional pixels appear as black spots in the display. It only takes a small number of non-functional pixels to cause a display to be non-marketable. Hence, it is worthwhile to know whether the baseplate 21 has defective pixels before completing the assembly of the display device.

The amount of time required for the test varies with the amount of time needed to measure the pulse, the time needed for the pulse to reach equilibrium and decay, and the time needed to process the data. However, the test method of the present invention is independent of address method (e.g., passive or active circuitry) or current regulation schemes.

In an alternative embodiment, multiple pixels are turned on at the same time. For example, one desires to test a group of five pixels. In such a case, four of the pixels are turned on at the same time (e.g., P₁, P₂, P₃, P₄) , and one pixel (P₅) remains off, and the current emitted is measured. Then, a different subset of the same five pixels is turned on (e.g., P₁, P₂, P₃, P₅), and a different one of the pixels remains off (P₄), and the current is measured. Preferably, the number of pixels 22 tested at one time is less than 10.

The current emitted from the first subset is then compared with that of the second subset, or with the current from a subset known to contain working pixels. Then as different combinations of pixel groups are turned on, the functionality of those pixels is determined from the expected value.

This approach is especially useful in those situations where the current emitted from one pixel 22 is so small that accurate measurement is difficult due to background noise in the system. In this embodiment, the total current measured is larger because several pixels are tested at once.

Additionally, using the above-described approach, it is possible to measure the total current emitted from a group of pixels. So, a bulk value is obtained for a specified number of pixels. The total value is compared to a known or expected value. The measurement determines whether a particular group of pixels is non-functional. This is useful when there is a low current emitted per pixel 22, but it does not involve the sorting of the combination measurement as in the above described approach.

The measurement techniques of the present invention include testing either baseplates 21 which are disposed in a vacuum environment with a separate anode or an integrated anode 16.

The testing scheme of the present invention is repeatable with optical, as opposed to electrical measurements. The anode 16 is coated with a material, preferably a phosphor 19, that luminesces under electron bombardment 17. An optical detector, such as a photodiode, is disposed over the anode 16. When the electrons from a pixel 22 or group of pixels cause the anode 16 to luminesce, the photons 23 are measured by the detector, and the information is recorded, as illustrated in FIG. 4.

As with the electrical measurements previously described, the magnitude, shape, rise time, and duration of the pulse are parameters which can be compared to those of a known good pulse, thereby allowing the pixel functionality to be determined. As with the other methods, this embodiment is useful in assembled displays, or with cathode emitters disposed in a vacuum. However, a difference in the timing sequence is present, as it would depend on the decay time of the luminescing material, as well as the frequency response time of the detector used.

FIG. 5 is a flow-chart which depicts the flow of a wafer or substrate through the test apparatus of the present invention. Although testing is possible on individual baseplates, a more efficient and cost-effective approach is to test the device while it is still in wafer form. This allows higher throughput and reduces the cost by eliminating the processing of defective baseplates 21.

Any practical evaluation of a field emission device, must be done under vacuum. The quality of the vacuum affects the performance and the lifetime of field emitters 13. A pressure of 1×10⁻⁸ Torr is desired for testing procedures. In addition, some form is also desired.

Because silicon tips 13 are often used in field emission devices, oxidation of the silicon affects the emission characteristics. The oxide layer increases the work function, and thus, increases the required operating voltage. The current at a given voltage increases dramatically after burnin. This is the result of the removal of the oxide from the tip. Therefore, some processing of the wafer, such as a hydrogen plasma clean, is preferred prior to testing.

A vacuum bake has been found to improve performance in other emitter types. This is due to the removal of adsorbates which increase the work function. Removal of the adsorbates also reduces the likelihood that the emitters 13 will fail.

Die or baseplates 21 are pre-tested for shorts or other defects. The pre-testing is performed at a station at atmospheric pressure. The die is loaded into a high tolerance fixture which is vacuum, plasma, and high temperature compatible.

The fixtured die is loaded into a processing station which includes chambers for pump down, plasma scrub, vacuum bake, and/or other suitable preparation processes, after which the die is transferred to a testing chamber.

One embodiment of the present invention comprises a probe assembly, referred to as an "anode card," comprises electrical connections corresponding to emission control pads. An integrated anode plate or phosphor screen is aligned to the fixture containing the device or die under test (DUT). Electrical connections are releasably made to the die under test, and each emitter or group of emitters is tested for emission characteristics. Springs are preferably used to hold the die in position during test. The fixtured die are removed form the test chamber, and the die having satisfactory characteristics are packaged into a display device, for example.

The ability to remove the die from the socket after the testing process is a significant improvement over the known methods. This enables the die to be tested before it is assembled into a completed display. Prior to the development of the present invention, baseplates were hard-wired or otherwise processed in order for testing to be undertaken. The hard-wiring implies that the display has to be completely assembled.

Another embodiment of the present invention comprises an automated ultra-high vacuum wafer probe station. The probe station comprises a load-lock which handles a cassette of wafers. A single wafer is loaded into the ultra-high vacuum transfer chamber on a transfer trolley. The wafer is then loaded into a clean chamber where a combination of plasma clean and/or vacuum bake is performed. The wafer is then moved through the transfer chamber to a probe chamber where the wafer is clamped and staged for testing. The wafer staging system has an x, y, and z axis and rotational movement.

The wafer is aligned to a probe card having pins; the number of pins varies with type and size of display. For example, if the baseplate has built-in driver circuitry 5-30 pins may be required. If it has no circuitry, thousands of pins are required. The wafer is raised until the pins make electrical connection to bond pads. The bond pads have a size substantially in the range of 100×100 μm. The preferred movement resolution is +/-20 μm. The probe card of the present invention, hereinafter referred to as an "anode card," also comprises an anode plate which is preferably glass coated with film and a phosphor. The phosphor film is preferably transparent, such as indium oxide, tin oxide, and indium tin oxide. However, other coatings such as chromium nickel and aluminum can also be used.

The phosphor is used to provide visual verification of emitter operation and emitter burn-in. The anode is preferably transparent to allow visual alignment of the card.

Alternatively, other conductors known in the art may be used as anodes. Some of these conductors will be opaque. The anode is preferably disposed approximately 1000 μm above the wafer, and preferably biased at 2000-3000V, but may be biased from 500V to 30,000V.

In the case of a separate anode, the position of the anode must be close enough that the electrons bombard only the anode, in order to prevent static noise or charging and breakdown of the insulators. Once the card is aligned to a reference die on the wafer, the automated testing system tests the baseplate of the first die, and then moves onto the next die on the wafer.

FIGS. 6 and 7 illustrate the anode assemblies of the present invention. The anode card comprises a phosphor coated anode, and contact pins all under high vacuum.

If more than 5 bad pixels are found in a baseplate, or if there are a few closely spaced defective pixels, the die will be considered defective, and testing of that die will cease. A re-check may alternatively be performed.

The analysis is performed by measuring the current pulse on the anode and comparing that with the pulse of a known good pixel. The testing procedure of the present invention provides a high speed approach to pixel yield analysis, which was previously unavailable. The testing procedure of the present invention greatly increases the viability of field emission displays by improving yield analysis, and providing feedback for process development.

To further speed up the process, the anode is divided into segments, so that more than one pixel is tested at a time. Alternatively, multiple probe card assemblies are used to test more than one die at a time.

The wafer is removed from the socket, and processing of the display or other device proceeds.

All of the U.S. Patents cited herein are hereby incorporated by reference herein as if set forth in their entirety.

While the particular process as herein shown and disclosed in detail is fully capable of obtaining the objects and advantages herein before stated, it is to be understood that it is merely illustrative of the presently preferred embodiments of the invention and that no limitations are intended to the details of construction or design herein shown other than as described in the appended claims.

For example, one having ordinary skill in the art will realize that the testing hardware and procedures described herein are useful, with modifications, to test both individual and groups of baseplates and other devices. 

What is claimed is:
 1. A method of testing a field emitter array, said method comprising the following steps of:releasably disposing a wafer in a socket, said wafer having at least one baseplate comprising cathode emitters arranged in pixels, and an extraction grid spaced above said cathode emitters, said socket having pads; contacting said socket pads with test pins; addressing each of said pixels individually, to cause said cathode emitters to emit electrons in a current; collecting and measuring said current from each of said pixels on an anode screen, and comparing each said current measurement to an expected value.
 2. The method of testing a field emitter array, according to claim 1, wherein said pads are approximately 100×100 μm in size.
 3. The method of testing a field emitter array, according to claim 1, wherein said cathode emitters have been burned in.
 4. The method of testing a field emitter array, according to claim 1, wherein said cathode emitters are cleaned in at least one of hydrogen (H₂) and argon (Ar).
 5. The method of testing a field emitter array, according to claim 1, wherein said cathode emitters are baked prior to said addressing.
 6. The method of testing a field emitter array, according to claim 1, further comprising the step of:removing said wafer from said socket.
 7. The method of electrically testing pixel functionality, said method comprising the following steps of:releasably disposing a wafer in a socket, said wafer having at least one baseplate comprised of cathode emitters arranged in pixels said socket having pads: contacting said socket pads with test pins; addressing each of said pixels individually, thereby causing said cathode emitters to emit electrons in a current; and collecting said current from each of said pixels on an anode screen, wherein a very high vacuum exists between said socket and said anode screen, said very high vacuum being below 1 motor of pressure.
 8. The method of electrically testing pixel functionality, according to claim 7, wherein said pads are approximately 100×100 μm in size.
 9. The method of electrically testing pixel functionality, according to claim 7, wherein said cathode emitters have been burned in.
 10. The method of electrically testing pixel functionality, according to claim 7, wherein said cathode emitters are cleaned in at least one of hydrogen (H₂) and argon (Ar).
 11. The method of electrically testing pixel functionality, according to claim 7, wherein said cathode emitters are baked prior to said addressing.
 12. The method of electrically testing pixel functionality, according to claim 7, further comprising the step of:removing said wafer from said socket.
 13. A method of electrically testing pixel functionality in a display, said method comprising the following steps of:releasably disposing a wafer in a socket, said wafer having at least one baseplate comprised of pixels, each of said pixels comprising at least one emitter, said socket having pads; contacting said socket pads with test pins; addressing each of said pixels individually, thereby causing said pixels to emit electrons in a current; collecting said current from each of said pixels on an anode; and measuring said current.
 14. The method of electrically testing pixel functionality, according to claim 13, wherein said pads are approximately 100×100 μm in size.
 15. The method of electrically testing pixel functionality, according to claim 13, wherein said pixels have been burned in.
 16. The method of electrically testing pixel functionality, according to claim 13, wherein said pixels are baked prior to said addressing.
 17. The method of electrically testing pixel functionality, according to claim 13, further comprising the step of: removing said wafer from said socket. 